A separator for a secondary battery, including a porous polymer substrate; a porous coating layer on at least one surface of the porous polymer substrate. The porous coating layer includes a plurality of inorganic particles and a first binder polymer that interconnects and fixes the inorganic particles; and an adhesive layer on a surface of the porous coating layer opposite to the porous polymer substrate. The adhesive layer includes a second binder polymer, and the adhesive layer includes a first layer in contact with the surface of the porous coating layer opposite to the porous polymer substrate, and a second layer integrated with the first layer and the second layer faces an electrode. The second layer has an average pore size larger than the average pore size of the first layer. The separator for a secondary battery can improve the problem related with resistance, while ensuring adhesion to an electrode.

A secondary battery that generates or includes metal-ion contaminants selected from copper ions, manganese ions, nickel ions, cobalt ions, iron ions, aluminum ions, chrome ions, molybdenum ions, tin ions or combinations thereof, the battery comprising: an anode; a cathode; a coated or uncoated battery separator between the anode and the cathode, wherein the coated or uncoated battery separator comprises a trap layer; and an electrolyte. The battery improve yield rate of initial charge and aging process and exhibits prolonged useful life due to the separator, which reduces or eliminates metal-ion contamination in the battery.

A secondary battery that generates or includes metal-ion contaminants selected from copper ions, manganese ions, nickel ions, cobalt ions, iron ions, aluminum ions, chrome ions, molybdenum ions, tin ions or combinations thereof, the battery comprising: an anode; a cathode; a coated or uncoated battery separator between the anode and the cathode, wherein the coated or uncoated battery separator comprises a trap layer; and an electrolyte. The battery improve yield rate of initial charge and aging process and exhibits prolonged useful life due to the separator, which reduces or eliminates metal-ion contamination in the battery.

A negative electrode for a lithium secondary battery, a lithium secondary battery including the negative electrode, and a method for manufacturing the lithium secondary battery, where the negative electrode includes a negative electrode current collector; and a negative electrode active material layer on at least one surface of the negative electrode current collector. The negative electrode active material layer includes a Si-containing negative electrode active material, a conductive material and a first binder polymer. The Si-containing negative electrode active material has cracks formed after activation, and a second binder polymer is present in the cracks. The first binder polymer and the second binder polymer are heterogeneous (e.g., different from each other). The lithium secondary battery shows improved life characteristics.

A negative electrode for a lithium secondary battery, a lithium secondary battery including the negative electrode, and a method for manufacturing the lithium secondary battery, where the negative electrode includes a negative electrode current collector; and a negative electrode active material layer on at least one surface of the negative electrode current collector. The negative electrode active material layer includes a Si-containing negative electrode active material, a conductive material and a first binder polymer. The Si-containing negative electrode active material has cracks formed after activation, and a second binder polymer is present in the cracks. The first binder polymer and the second binder polymer are heterogeneous (e.g., different from each other). The lithium secondary battery shows improved life characteristics.

A method includes, by a folding station: receiving an anode assembly including anode collectors connected by anode interconnects and coated with a separator; receiving a cathode assembly including cathode collectors connected by cathode interconnects; locating a first anode collector over a folding stage; locating a first cathode collector over the first anode collector to form a first battery cell between the first anode collector and the first cathode collector; folding a first anode interconnect to locate a second anode collector over the first cathode collector to form a second battery cell between the first cathode collector and the second anode collector; folding a first cathode interconnect to locate a second cathode collector over the second anode collector to form a third battery cell between the second anode collector and the second cathode collector; wetting the separator with solvated ions; and loading the anode and cathode assemblies into a battery housing.

A method includes, by a folding station: receiving an anode assembly including anode collectors connected by anode interconnects and coated with a separator; receiving a cathode assembly including cathode collectors connected by cathode interconnects; locating a first anode collector over a folding stage; locating a first cathode collector over the first anode collector to form a first battery cell between the first anode collector and the first cathode collector; folding a first anode interconnect to locate a second anode collector over the first cathode collector to form a second battery cell between the first cathode collector and the second anode collector; folding a first cathode interconnect to locate a second cathode collector over the second anode collector to form a third battery cell between the second anode collector and the second cathode collector; wetting the separator with solvated ions; and loading the anode and cathode assemblies into a battery housing.

Provided is a pouch type secondary battery including a jelly roll in which a plurality of unit cells including a structure of a separator interposed between a positive electrode and a negative electrode are laminated, wherein a unit cell positioned in an outermost layer of the jelly roll includes a carbon dioxide adsorbent.

Novel or improved microporous single or multilayer battery separator membranes, separators, batteries including such membranes or separators, methods of making such membranes, separators, and/or batteries, and/or methods of using such membranes, separators and/or batteries are provided. In accordance with at least certain embodiments, a multilayer dry process polyethylene/polypropylene/polyethylene microporous separator which is manufactured using the inventive process which includes machine direction stretching followed by transverse direction stretching and a subsequent calendering step as a means to reduce the thickness of the multilayer microporous membrane, to reduce the percent porosity of the multilayer microporous membrane in a controlled manner and/or to improve transverse direction tensile strength. In a very particular embodiment, the inventive process produces a thin multilayer microporous membrane that is easily coated with polymeric-ceramic coatings, has excellent mechanical strength properties due to its polypropylene layer or layers and a thermal shutdown function due to its polyethylene layer or layers. The ratio of the thickness of the polypropylene and polyethylene layers in the inventive multilayer microporous membrane can be tailored to balance mechanical strength and thermal shutdown properties.

Novel or improved microporous single or multilayer battery separator membranes, separators, batteries including such membranes or separators, methods of making such membranes, separators, and/or batteries, and/or methods of using such membranes, separators and/or batteries are provided. In accordance with at least certain embodiments, a multilayer dry process polyethylene/polypropylene/polyethylene microporous separator which is manufactured using the inventive process which includes machine direction stretching followed by transverse direction stretching and a subsequent calendering step as a means to reduce the thickness of the multilayer microporous membrane, to reduce the percent porosity of the multilayer microporous membrane in a controlled manner and/or to improve transverse direction tensile strength. In a very particular embodiment, the inventive process produces a thin multilayer microporous membrane that is easily coated with polymeric-ceramic coatings, has excellent mechanical strength properties due to its polypropylene layer or layers and a thermal shutdown function due to its polyethylene layer or layers. The ratio of the thickness of the polypropylene and polyethylene layers in the inventive multilayer microporous membrane can be tailored to balance mechanical strength and thermal shutdown properties.